WO2012105331A1 - Solar cell module and method for manufacturing same - Google Patents

Solar cell module and method for manufacturing same Download PDF

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Publication number
WO2012105331A1
WO2012105331A1 PCT/JP2012/051149 JP2012051149W WO2012105331A1 WO 2012105331 A1 WO2012105331 A1 WO 2012105331A1 JP 2012051149 W JP2012051149 W JP 2012051149W WO 2012105331 A1 WO2012105331 A1 WO 2012105331A1
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WO
WIPO (PCT)
Prior art keywords
resin layer
solar cell
colored resin
transparent
mfr
Prior art date
Application number
PCT/JP2012/051149
Other languages
French (fr)
Japanese (ja)
Inventor
将規 前田
Original Assignee
三洋電機株式会社
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Filing date
Publication date
Application filed by 三洋電機株式会社 filed Critical 三洋電機株式会社
Priority to EP12742022.2A priority Critical patent/EP2672526B1/en
Priority to JP2012555789A priority patent/JP5949562B2/en
Priority to CN201280007213.6A priority patent/CN103348492B/en
Publication of WO2012105331A1 publication Critical patent/WO2012105331A1/en
Priority to US13/951,750 priority patent/US9698298B2/en
Priority to US15/603,452 priority patent/US9960313B2/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10018—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising only one glass sheet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10651—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer comprising colorants, e.g. dyes or pigments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10761—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing vinyl acetal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10798—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing silicone
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the present invention relates to a solar cell module and a manufacturing method thereof.
  • the solar cell module includes solar cells. Solar cells are likely to deteriorate due to contact with moisture and the like. For this reason, it is necessary to isolate a photovoltaic cell from outside air. Therefore, the photovoltaic cell is normally arrange
  • Patent Document 1 describes that a portion of the filler layer located between the back surface of the solar battery cell and the back surface side protective member is produced by a colored EVA film. Has been. Patent Document 1 describes that the use of a colored EVA film can increase the light use efficiency, thereby improving the photoelectric conversion efficiency.
  • the solar cell module described in Patent Document 1 can be manufactured, for example, by thermocompression bonding a laminate in which solar cells are arranged between a colored EVA film and a transparent EVA film.
  • This invention is made
  • a transparent substrate, a transparent resin layer, a solar battery cell, a colored resin layer, and a back sheet are laminated in this order.
  • the light receiving surface of the solar cell faces the transparent resin layer side.
  • the back surface of the solar battery cell faces the colored resin layer side.
  • the MFR of the transparent resin layer is smaller than the MFR of the colored resin layer.
  • a laminate is formed by laminating a transparent substrate, a transparent resin sheet, a solar cell, a colored resin sheet, and a back sheet in this order.
  • the light receiving surface of the solar battery cell faces the transparent resin sheet side.
  • the back surface of the solar battery cell faces the colored resin sheet side.
  • the transparent resin sheet has a higher viscosity than the colored resin sheet. Laminate the laminate while heating.
  • FIG. 1 is a schematic plan view of a solar cell module according to an embodiment of the present invention.
  • FIG. 2 is a schematic cross-sectional view taken along line II-II in FIG.
  • FIG. 3 is a schematic exploded sectional view of the laminate.
  • FIG. 1 is a schematic plan view of a solar cell module according to this embodiment.
  • FIG. 2 is a schematic cross-sectional view taken along line II-II in FIG.
  • the solar cell module 1 includes a transparent substrate 10 as a light receiving surface side protection member, a back sheet 11 as a back surface side protection member, a filler layer 13 as a resin layer, and a plurality of layers.
  • the solar battery cell unit 2 including the solar battery cell 12 is provided.
  • the solar cell module 1 may have a frame surrounding the periphery. Further, a terminal box for taking out electric power may be provided on the transparent substrate 10 or the back sheet 11.
  • the transparent substrate 10 is disposed on the light receiving surface 12 a side of the solar battery cell 12.
  • the transparent substrate 10 is a member that protects the solar cell unit 2 and ensures the mechanical strength of the solar cell module 1.
  • the transparent substrate 10 can be composed of, for example, a glass plate or a resin plate. Especially, it is preferable that the transparent substrate 10 is comprised with the glass plate. This is because the glass plate has high rigidity and light transmittance and is excellent in weather resistance.
  • the thickness of the transparent substrate 10 is not particularly limited.
  • the thickness of the transparent substrate 10 can be set to about 3 mm to 6 mm, for example.
  • the back sheet 11 faces the transparent substrate 10.
  • the back sheet 11 is disposed on the back surface 12 b side of the solar battery cell 12.
  • the back sheet 11 can be composed of, for example, a flexible resin sheet made of polyethylene terephthalate (PET) or the like.
  • PET polyethylene terephthalate
  • moisture permeability, etc. may be provided, for example.
  • the inorganic barrier layer can be formed of, for example, an inorganic oxide such as silicon oxide, aluminum oxide, or magnesium oxide.
  • the thickness of the back sheet 11 is not particularly limited.
  • the thickness of the back sheet 11 can be, for example, about 150 ⁇ m to 300 ⁇ m.
  • Solar cell unit 2 is arranged inside filler layer 13.
  • the solar cell unit 2 includes a plurality of solar cell strings 3 that are electrically connected to each other.
  • the solar cell string 3 has a plurality of solar cells 12.
  • the plurality of solar cells 12 are arranged in one direction and are electrically connected in series or in parallel by the wiring member 14. Specifically, the plurality of solar cells 12 are electrically connected in series or in parallel by the solar cells 12 adjacent in one direction being electrically connected by the wiring member 14.
  • the solar battery cell 12 has a photoelectric conversion part and a p-side electrode and an n-side electrode arranged on the photoelectric conversion part.
  • the photoelectric conversion unit is a member that generates carriers such as electrons and holes by receiving light.
  • the photoelectric conversion unit includes, for example, a crystalline semiconductor substrate having one conductivity type, and a p-type amorphous semiconductor layer and an n-type amorphous semiconductor layer disposed on the crystalline semiconductor substrate. It may be.
  • the photoelectric conversion part may have a semiconductor substrate in which the n-type dopant diffusion region and the p-type dopant diffusion region are exposed on the surface.
  • the photoelectric conversion unit includes a p-type or n-type crystalline semiconductor substrate, a p-type amorphous semiconductor layer and an n-type amorphous semiconductor layer formed on the crystalline semiconductor substrate, and a p-type amorphous semiconductor And an i-type amorphous semiconductor layer having a thickness that does not substantially contribute to power generation and is disposed between the semiconductor layer and the n-type amorphous semiconductor layer and the crystalline semiconductor substrate. Good.
  • the solar battery cell 12 may be a so-called back junction type solar battery cell in which both the p-side electrode and the n-side electrode are provided on the back surface of the photoelectric conversion unit.
  • Each material of the p-side electrode and the n-side electrode is not particularly limited as long as it is a conductive material.
  • Each of the p-side electrode and the n-side electrode can be composed of, for example, a metal such as silver, copper, aluminum, titanium, nickel, or chromium, or an alloy containing one or more of these metals.
  • each of the p-side electrode and the n-side electrode may be composed of a stacked body of a plurality of conductive layers made of the above metal or alloy, for example.
  • the filler layer 13 as a resin layer is filled between the transparent substrate 10 and the back sheet 11.
  • the filler layer 13 is a member for sealing the solar battery cell unit 2. For this reason, the filler layer 13 may be called a sealing layer.
  • the filler layer 13 is composed of a laminate including a colored resin layer 13a and a transparent resin layer 13b laminated on the colored resin layer 13a.
  • the solar cell unit 2 is arranged at the interface between the colored resin layer 13a and the transparent resin layer 13b.
  • the solar cell unit 2 is arranged so that the light receiving surface 12a of the solar cell 12 faces the transparent resin layer 13b side and the back surface 12b faces the colored resin layer 13a side.
  • the filler layer 13 as a resin layer is constituted by a laminate including a colored resin layer 13a and a transparent resin layer 13b.
  • the resin layer is not particularly limited as long as it has a colored resin layer located on the back surface side and a transparent resin layer located on the light receiving surface side and adjacent to the colored resin layer.
  • the resin layer may have a resin layer other than the colored resin layer and the transparent resin layer.
  • each of the colored resin layer and the transparent resin layer may be composed of a plurality of resin layers.
  • the transparent resin layer 13 b is disposed between the light receiving surface 12 a of the solar battery cell 12 and the transparent substrate 10.
  • the transparent resin layer 13 b is a resin layer that transmits light in a wavelength region used for photoelectric conversion in the solar battery cell 12.
  • the transparent resin layer 13b preferably has an average light transmittance of 85% or more in a wavelength region of 400 nm to 1100 nm.
  • the colored resin layer 13 a is disposed between the back surface 12 b of the solar battery cell 12 and the back sheet 11.
  • the colored resin layer 13a may be formed of, for example, a resin composition containing a resin and a colorant.
  • the colored resin layer 13a may be made of a colored resin such as a white resin.
  • the colorant include, for example, white colorants such as titanium oxide particles and calcium carbonate particles, blue colorants such as ultramarine, black colorants such as carbon black, and coloring such as glass beads and light scattering materials.
  • white colorants such as titanium oxide particles and calcium carbonate particles
  • blue colorants such as ultramarine
  • black colorants such as carbon black
  • coloring such as glass beads and light scattering materials.
  • white titanium oxide particles are preferably used as the colorant.
  • the melt flow rate (MFR) of the transparent resin layer 13b is smaller than the MFR of the colored resin layer 13a. That is, the resin constituting the transparent resin layer 13b and the resin constituting the colored resin layer 13a are combined such that the melt flow rate (MFR) of the transparent resin layer 13b is smaller than the MFR of the colored resin layer 13a. ing.
  • the melt flow rate (MFR) of the transparent resin layer 13b is more preferably 0.7 g / 10 min or less and preferably 1.0 g / 10 min or less than the MFR of the colored resin layer 13a.
  • the resin constituting the transparent resin layer 13b was selected from the group consisting of, for example, an ethylenically unsaturated silane compound, a copolymer of an ethylenically unsaturated silane compound and an ⁇ -olefin, and a silane-modified resin. At least one is preferable.
  • Examples of the ethylenically unsaturated silane compound include vinyltrimethoxysilane, vinyltriethoxysilane, vinyltripropoxysilane, and vinyltricarboxysilane.
  • Examples of the ⁇ -olefin include ethylene, propylene, 1-butene, isobutylene, 1-pentene and 2-methyl-1-butene.
  • silane-modified resin examples include silane-modified ethylene, silane-modified urethane, silane-modified phenol, and silane-modified epoxy.
  • the resin constituting the colored resin layer 13a is, for example, ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, silicone resin, epoxy resin, polyvinyl butyral, ethylene vinyl alcohol copolymer, acrylic resin, polyethylene. And at least one selected from the group consisting of polypropylene.
  • melt flow rate (MFR) is a numerical value representing the fluidity of a thermoplastic resin during melting.
  • melt flow rate (MFR) can be performed by the following method. That is, the extrudate is cut at regular time intervals, a series of cut amounts are measured, and the melt flow rate (MFR) can be obtained by the following formula (1).
  • MFR Melt flow rate (g / 10 min)
  • m Average mass of the cut piece
  • t Sample cut time interval (seconds)
  • the transparent resin sheet 22 for constituting the transparent resin layer 13b the transparent resin sheet 22 for constituting the transparent resin layer 13b, the solar cell unit 2, and the colored resin sheet for constituting the colored resin layer 13a.
  • the laminated body 30 is formed by laminating 21 and the back sheet 11 in this order (laminated body forming step).
  • the solar cell module 1 can be completed by laminating the laminate 30 while heating (laminating step).
  • the melt flow rate (MFR) of the transparent resin layer 13b is smaller than the MFR of the colored resin layer 13a. For this reason, as the colored resin sheet 21, a resin sheet having a viscosity lower than that of the transparent resin sheet is used in the laminating step.
  • the part located at the end of the laminated body of the transparent resin sheet and the colored resin sheet is deformed and thinned. For this reason, in a lamination process, a part of part located in the laminated body edge part of a transparent resin sheet and a colored resin sheet flows toward the laminated body center.
  • the transparent substrate is relatively hard, while the resin sheet has flexibility. For this reason, the colored resin sheet provided on the resin sheet side tends to flow toward the center of the laminate and the transparent substrate side. Therefore, there is a possibility that the colored resin sheet may wrap around the light receiving surface of the solar battery cell positioned at the outer edge of the solar battery cell unit.
  • the MFR of the transparent resin layer 13b is smaller than the MFR of the colored resin layer 13a, and the viscosity of the colored resin sheet 21 is lower than the viscosity of the transparent resin sheet 22 in the laminating step. Therefore, the colored resin sheet 21 that attempts to wrap around the light receiving surface 12a of the solar battery cell 12 in the laminating process is repelled by the transparent resin sheet 22 having a high viscosity. As a result, it is possible to effectively suppress the colored resin sheet 21 from going around the light receiving surface 12a of the solar battery cell 12. Therefore, the solar cell module 1 having improved photoelectric conversion efficiency can be manufactured.

Abstract

This solar cell module (1) has a transparent substrate (10), a transparent resin sheet (22), solar cells (12), colored resin sheet (21), and back sheet (11) stacked in that order and is manufactured by laminating this stack. The MFR of the transparent resin sheet is characterized by being smaller than the MFR of the colored resin sheet, whereby the colored resin sheet which tends to wrap around on top of a light receiving surface (12a) of this solar cell in the laminating process is repelled by the transparent resin sheet, which has a high viscosity, and the wrapping of the colored resin sheet on top of the light receiving surface is effectively suppressed, preventing a reduction in the light receiving efficiency.

Description

太陽電池モジュール及びその製造方法Solar cell module and manufacturing method thereof
　本発明は、太陽電池モジュール及びその製造方法に関する。 The present invention relates to a solar cell module and a manufacturing method thereof.
　近年、環境負荷が小さいエネルギー源として、太陽電池モジュールが大いに注目されている。 In recent years, solar cell modules have attracted a great deal of attention as an energy source with a low environmental load.
　太陽電池モジュールは、太陽電池セルを備えている。太陽電池セルは、水分などとの接触により劣化しやすい。このため、太陽電池セルを外気から隔離する必要がある。従って、太陽電池セルは、通常、表裏を保護するための保護部材の間に設けられている充填剤層の内部に配置されている。 The solar cell module includes solar cells. Solar cells are likely to deteriorate due to contact with moisture and the like. For this reason, it is necessary to isolate a photovoltaic cell from outside air. Therefore, the photovoltaic cell is normally arrange | positioned inside the filler layer provided between the protection members for protecting the front and back.
　この充填剤層に関し、例えば下記の特許文献１には、充填剤層のうち、太陽電池セルの裏面と裏面側保護部材との間に位置している部分を着色ＥＶＡフィルムにより作製することが記載されている。また、特許文献１には、着色ＥＶＡフィルムを用いることにより、光の利用効率が高められるため、光電変換効率を向上できる旨が記載されている。 Regarding this filler layer, for example, the following Patent Document 1 describes that a portion of the filler layer located between the back surface of the solar battery cell and the back surface side protective member is produced by a colored EVA film. Has been. Patent Document 1 describes that the use of a colored EVA film can increase the light use efficiency, thereby improving the photoelectric conversion efficiency.
特開２００３－２５８２８３号公報JP 2003-258283 A
　特許文献１に記載の太陽電池モジュールは、例えば、着色ＥＶＡフィルムと、透明ＥＶＡフィルムとの間に太陽電池セルが配置された積層体を加熱圧着することにより製造することができる。 The solar cell module described in Patent Document 1 can be manufactured, for example, by thermocompression bonding a laminate in which solar cells are arranged between a colored EVA film and a transparent EVA film.
　しかしながら、このような製造方法で特許文献１に記載の太陽電池モジュールを製造した場合、着色ＥＶＡが太陽電池セルの受光面側に回り込んでしまうという懸念がある。着色ＥＶＡが太陽電池セルの受光面側に回り込んでしまうと、受光面に入射しようとする光の一部が着色ＥＶＡにより遮られてしまう。従って、受光面における受光効率が低下してしまうため、太陽電池モジュールの出力が低くなってしまうという問題が生じる。 However, when the solar cell module described in Patent Document 1 is manufactured by such a manufacturing method, there is a concern that the colored EVA wraps around the light receiving surface side of the solar cell. If the colored EVA wraps around the light receiving surface side of the solar battery cell, a part of the light entering the light receiving surface is blocked by the colored EVA. Therefore, since the light receiving efficiency on the light receiving surface is lowered, there arises a problem that the output of the solar cell module is lowered.
　本発明は、斯かる点に鑑みてなされたものであり、その目的は、改善された出力を有する太陽電池モジュール及びその製造方法を提供することにある。 This invention is made | formed in view of such a point, The objective is to provide the solar cell module which has the improved output, and its manufacturing method.
　本発明に係る太陽電池モジュールでは、透明基板と、透明樹脂層と、太陽電池セルと、着色樹脂層と、バックシートとがこの順番で積層されている。太陽電池セルの受光面が透明樹脂層側を向いている。太陽電池セルの裏面が着色樹脂層側を向いている。透明樹脂層のＭＦＲは、着色樹脂層のＭＦＲよりも小さい。 In the solar battery module according to the present invention, a transparent substrate, a transparent resin layer, a solar battery cell, a colored resin layer, and a back sheet are laminated in this order. The light receiving surface of the solar cell faces the transparent resin layer side. The back surface of the solar battery cell faces the colored resin layer side. The MFR of the transparent resin layer is smaller than the MFR of the colored resin layer.
  本発明に係る太陽電池モジュールの製造方法では、透明基板と、透明樹脂シートと、太陽電池セルと、着色樹脂シートと、バックシートとをこの順番で積層させた積層体を形成する。太陽電池セルの受光面が透明樹脂シート側を向いている。太陽電池セルの裏面が着色樹脂シート側を向いている。透明樹脂シートが着色樹脂シートよりも高い粘度を有する。積層体を加熱しながらラミネートする。 In the method for manufacturing a solar cell module according to the present invention, a laminate is formed by laminating a transparent substrate, a transparent resin sheet, a solar cell, a colored resin sheet, and a back sheet in this order. The light receiving surface of the solar battery cell faces the transparent resin sheet side. The back surface of the solar battery cell faces the colored resin sheet side. The transparent resin sheet has a higher viscosity than the colored resin sheet. Laminate the laminate while heating.
　本発明によれば、改善された出力を有する太陽電池モジュール及びその製造方法を提供することができる。 According to the present invention, it is possible to provide a solar cell module having an improved output and a manufacturing method thereof.
図１は、本発明の一実施形態に係る太陽電池モジュールの略図的平面図である。FIG. 1 is a schematic plan view of a solar cell module according to an embodiment of the present invention. 図２は、図１の線ＩＩ－ＩＩにおける略図的断面図である。FIG. 2 is a schematic cross-sectional view taken along line II-II in FIG. 図３は、積層体の略図的分解断面図である。FIG. 3 is a schematic exploded sectional view of the laminate.
　以下、本発明を実施した好ましい形態の一例について説明する。但し、下記の実施形態は、単なる一例である。本発明は、以下の実施形態に何ら限定されない。 Hereinafter, an example of a preferable embodiment in which the present invention is implemented will be described. However, the following embodiment is merely an example. The present invention is not limited to the following embodiments.
　また、以下の実施形態において参照する各図面において、実質的に同一の機能を有する部材は同一の符号で参照することとする。また、実施形態において参照する図面は、模式的に記載されたものであり、図面に描画された物体の寸法の比率などは、現実の物体の寸法の比率などとは異なる場合がある。図面相互間においても、物体の寸法比率等が異なる場合がある。具体的な物体の寸法比率等は、以下の説明を参酌して判断されるべきである。 In the drawings referred to in the following embodiments, members having substantially the same function are referred to by the same reference numerals. The drawings referred to in the embodiments are schematically described, and the ratio of the dimensions of the objects drawn in the drawings may be different from the ratio of the dimensions of the actual objects. The dimensional ratio of the object may be different between the drawings. The specific dimensional ratio of the object should be determined in consideration of the following description.
　図１は、本実施形態に係る太陽電池モジュールの略図的平面図である。図２は、図１の線ＩＩ－ＩＩにおける略図的断面図である。図１及び図２に示すように、太陽電池モジュール１は、受光面側保護部材としての透明基板１０と、裏面側保護部材としてのバックシート１１と、樹脂層としての充填剤層１３と、複数の太陽電池セル１２を含む太陽電池セルユニット２とを備えている。 FIG. 1 is a schematic plan view of a solar cell module according to this embodiment. FIG. 2 is a schematic cross-sectional view taken along line II-II in FIG. As shown in FIGS. 1 and 2, the solar cell module 1 includes a transparent substrate 10 as a light receiving surface side protection member, a back sheet 11 as a back surface side protection member, a filler layer 13 as a resin layer, and a plurality of layers. The solar battery cell unit 2 including the solar battery cell 12 is provided.
　なお、太陽電池モジュール１は周囲を囲繞する枠体を有していても良い。また、透明基板１０またはバックシート１１の上に、電力取り出し用の端子ボックスを有していても良い。 In addition, the solar cell module 1 may have a frame surrounding the periphery. Further, a terminal box for taking out electric power may be provided on the transparent substrate 10 or the back sheet 11.
　（透明基板１０）
　透明基板１０は、太陽電池セル１２の受光面１２ａ側に配されている。透明基板１０は、太陽電池セルユニット２を保護すると共に、太陽電池モジュール１の機械的強度を担保する部材である。 (Transparent substrate 10)
The transparent substrate 10 is disposed on the light receiving surface 12 a side of the solar battery cell 12. The transparent substrate 10 is a member that protects the solar cell unit 2 and ensures the mechanical strength of the solar cell module 1.
　透明基板１０は、例えば、ガラス板や樹脂板などにより構成することができる。なかでも、透明基板１０は、ガラス板により構成されていることが好ましい。ガラス板は、剛性及び光透過率が高く、かつ耐候性に優れているからである。 The transparent substrate 10 can be composed of, for example, a glass plate or a resin plate. Especially, it is preferable that the transparent substrate 10 is comprised with the glass plate. This is because the glass plate has high rigidity and light transmittance and is excellent in weather resistance.
　なお、透明基板１０の厚さは、特に限定されない。透明基板１０の厚さは、例えば、３ｍｍ～６ｍｍ程度とすることができる。 Note that the thickness of the transparent substrate 10 is not particularly limited. The thickness of the transparent substrate 10 can be set to about 3 mm to 6 mm, for example.
　（バックシート１１）
　バックシート１１は、透明基板１０と対向している。バックシート１１は、太陽電池セル１２の裏面１２ｂ側に配されている。バックシート１１は、例えば、ポリエチレンテレフタレート（ＰＥＴ）などからなる可撓性を有する樹脂シートなどにより構成することができる。なお、バックシート１１を構成する樹脂シートの内部には、例えば、アルミニウム箔などの金属箔や、水分透過性が低い無機バリア層等が設けられていてもよい。無機バリア層は、例えば、酸化珪素、酸化アルミニウム、酸化マグネシウム等の無機酸化物などにより形成することができる。 (Back sheet 11)
The back sheet 11 faces the transparent substrate 10. The back sheet 11 is disposed on the back surface 12 b side of the solar battery cell 12. The back sheet 11 can be composed of, for example, a flexible resin sheet made of polyethylene terephthalate (PET) or the like. In addition, inside the resin sheet which comprises the back sheet | seat 11, metal foils, such as aluminum foil, an inorganic barrier layer with a low water | moisture permeability, etc. may be provided, for example. The inorganic barrier layer can be formed of, for example, an inorganic oxide such as silicon oxide, aluminum oxide, or magnesium oxide.
　なお、バックシート１１の厚さは、特に限定されない。バックシート１１の厚さは、例えば、１５０μｍ～３００μｍ程度とすることができる。 Note that the thickness of the back sheet 11 is not particularly limited. The thickness of the back sheet 11 can be, for example, about 150 μm to 300 μm.
　（太陽電池セルユニット２）
　充填剤層１３の内部には、太陽電池セルユニット２が配置されている。太陽電池セルユニット２は、互いに電気的に接続されている複数の太陽電池セルストリング３を備えている。太陽電池セルストリング３は、複数の太陽電池セル１２を有する。複数の太陽電池セル１２は、一の方向に配列され、配線材１４によって直列または並列に電気的に接続されている。具体的には、複数の太陽電池セル１２は、一の方向において隣り合う太陽電池セル１２同士が配線材１４によって電気的に接続されることによって、直列または並列に電気的に接続されている。 (Solar cell unit 2)
Solar cell unit 2 is arranged inside filler layer 13. The solar cell unit 2 includes a plurality of solar cell strings 3 that are electrically connected to each other. The solar cell string 3 has a plurality of solar cells 12. The plurality of solar cells 12 are arranged in one direction and are electrically connected in series or in parallel by the wiring member 14. Specifically, the plurality of solar cells 12 are electrically connected in series or in parallel by the solar cells 12 adjacent in one direction being electrically connected by the wiring member 14.
　太陽電池セル１２は、光電変換部と、光電変換部の上に配されたｐ側電極及びｎ側電極とを有する。光電変換部は、受光することによって電子や正孔などのキャリアを生成させる部材である。光電変換部は、例えば、一の導電型を有する結晶性半導体基板と、その結晶性半導体基板の上に配されているｐ型非晶質半導体層及びｎ型非晶質半導体層とを有するものであってもよい。また、光電変換部は、ｎ型ドーパント拡散領域とｐ型ドーパント拡散領域とが表面に露出している半導体基板を有するものであってもよい。 The solar battery cell 12 has a photoelectric conversion part and a p-side electrode and an n-side electrode arranged on the photoelectric conversion part. The photoelectric conversion unit is a member that generates carriers such as electrons and holes by receiving light. The photoelectric conversion unit includes, for example, a crystalline semiconductor substrate having one conductivity type, and a p-type amorphous semiconductor layer and an n-type amorphous semiconductor layer disposed on the crystalline semiconductor substrate. It may be. Moreover, the photoelectric conversion part may have a semiconductor substrate in which the n-type dopant diffusion region and the p-type dopant diffusion region are exposed on the surface.
　光電変換部は、ｐ型またはｎ型の結晶性半導体基板と、結晶性半導体基板の上に形成されているｐ型非晶質半導体層及びｎ型非晶質半導体層と、ｐ型非晶質半導体層及びｎ型非晶質半導体層と結晶性半導体基板との間に配されている、発電に実質的に寄与しない程度の厚みのｉ型非晶質半導体層とを備えるものであってもよい。 The photoelectric conversion unit includes a p-type or n-type crystalline semiconductor substrate, a p-type amorphous semiconductor layer and an n-type amorphous semiconductor layer formed on the crystalline semiconductor substrate, and a p-type amorphous semiconductor And an i-type amorphous semiconductor layer having a thickness that does not substantially contribute to power generation and is disposed between the semiconductor layer and the n-type amorphous semiconductor layer and the crystalline semiconductor substrate. Good.
　また、太陽電池セル１２は、ｐ側電極及びｎ側電極の両方が光電変換部の裏面の上に設けられている所謂裏面接合型の太陽電池セルであってもよい。 Also, the solar battery cell 12 may be a so-called back junction type solar battery cell in which both the p-side electrode and the n-side electrode are provided on the back surface of the photoelectric conversion unit.
　ｐ側電極及びｎ側電極のそれぞれの材質は、導電材料である限りにおいて特に限定されない。ｐ側電極及びｎ側電極のそれぞれは、例えば、銀、銅、アルミニウム、チタン、ニッケル、クロムなどの金属や、それらの金属のうちの一種以上を含む合金により構成することができる。また、ｐ側電極及びｎ側電極のそれぞれは、例えば、上記金属や合金からなる複数の導電層の積層体により構成されていてもよい。 Each material of the p-side electrode and the n-side electrode is not particularly limited as long as it is a conductive material. Each of the p-side electrode and the n-side electrode can be composed of, for example, a metal such as silver, copper, aluminum, titanium, nickel, or chromium, or an alloy containing one or more of these metals. In addition, each of the p-side electrode and the n-side electrode may be composed of a stacked body of a plurality of conductive layers made of the above metal or alloy, for example.
　（充填剤層１３）
　樹脂層として充填剤層１３は、透明基板１０とバックシート１１との間に充填されている。この充填剤層１３は、太陽電池セルユニット２を封止するための部材である。このため、充填剤層１３は、封止層と呼ばれることもある。 (Filler layer 13)
The filler layer 13 as a resin layer is filled between the transparent substrate 10 and the back sheet 11. The filler layer 13 is a member for sealing the solar battery cell unit 2. For this reason, the filler layer 13 may be called a sealing layer.
　充填剤層１３は、着色樹脂層１３ａと、着色樹脂層１３ａの上に積層されている透明樹脂層１３ｂとを含む積層体により構成されている。これら着色樹脂層１３ａと透明樹脂層１３ｂとの間の界面に太陽電池セルユニット２が配されている。太陽電池セルユニット２は、太陽電池セル１２の受光面１２ａが透明樹脂層１３ｂ側を向き、裏面１２ｂが着色樹脂層１３ａ側を向くように配されている。 The filler layer 13 is composed of a laminate including a colored resin layer 13a and a transparent resin layer 13b laminated on the colored resin layer 13a. The solar cell unit 2 is arranged at the interface between the colored resin layer 13a and the transparent resin layer 13b. The solar cell unit 2 is arranged so that the light receiving surface 12a of the solar cell 12 faces the transparent resin layer 13b side and the back surface 12b faces the colored resin layer 13a side.
　なお、本実施形態では、樹脂層としての充填剤層１３が着色樹脂層１３ａと透明樹脂層１３ｂとからなる積層体により構成されている。但し、本発明においては、樹脂層は、裏面側に位置する着色樹脂層と、受光面側に位置し、着色樹脂層に隣接する透明樹脂層とを有する限りにおいて特に限定されない。樹脂層は、着色樹脂層及び透明樹脂層以外の樹脂層を有していてもよい。また、着色樹脂層及び透明樹脂層のそれぞれが複数の樹脂層により構成されていてもよい。 In the present embodiment, the filler layer 13 as a resin layer is constituted by a laminate including a colored resin layer 13a and a transparent resin layer 13b. However, in the present invention, the resin layer is not particularly limited as long as it has a colored resin layer located on the back surface side and a transparent resin layer located on the light receiving surface side and adjacent to the colored resin layer. The resin layer may have a resin layer other than the colored resin layer and the transparent resin layer. Moreover, each of the colored resin layer and the transparent resin layer may be composed of a plurality of resin layers.
　透明樹脂層１３ｂは、太陽電池セル１２の受光面１２ａと透明基板１０との間に配置されている。ここで、透明樹脂層１３ｂは、太陽電池セル１２における光電変換に使用される波長域の光を透過させる樹脂層である。透明樹脂層１３ｂは、４００ｎｍ～１１００ｎｍの波長域における平均光透過率が８５％以上のものであることが好ましい。 The transparent resin layer 13 b is disposed between the light receiving surface 12 a of the solar battery cell 12 and the transparent substrate 10. Here, the transparent resin layer 13 b is a resin layer that transmits light in a wavelength region used for photoelectric conversion in the solar battery cell 12. The transparent resin layer 13b preferably has an average light transmittance of 85% or more in a wavelength region of 400 nm to 1100 nm.
　一方、着色樹脂層１３ａは、太陽電池セル１２の裏面１２ｂとバックシート１１との間に配置されている。着色樹脂層１３ａは、例えば、樹脂と、着色剤とを含む樹脂組成物により形成されていてもよい。また、着色樹脂層１３ａは、例えば、白色樹脂などの有色樹脂により構成されていてもよい。 On the other hand, the colored resin layer 13 a is disposed between the back surface 12 b of the solar battery cell 12 and the back sheet 11. The colored resin layer 13a may be formed of, for example, a resin composition containing a resin and a colorant. The colored resin layer 13a may be made of a colored resin such as a white resin.
　着色剤の具体例としては、例えば、酸化チタン粒子、炭酸カルシウム粒子などの白色の着色剤、ウルトラマリン等の青色着色剤、カーボンブラック等の黒色着色剤、ガラスビーズや光散乱材などの、着色樹脂層１３ａを乳白色にさせる着色剤等が挙げられる。これらの中でも、白色の酸化チタン粒子が着色剤として好ましく用いられる。白色の酸化チタン粒子を着色樹脂層１３ａに含ませることにより、着色樹脂層１３ａにおいて光が散乱しやすくなり、太陽電池モジュール１の光電変換効率をより高めることができるためである。 Specific examples of the colorant include, for example, white colorants such as titanium oxide particles and calcium carbonate particles, blue colorants such as ultramarine, black colorants such as carbon black, and coloring such as glass beads and light scattering materials. Examples thereof include a colorant that makes the resin layer 13a milky white. Among these, white titanium oxide particles are preferably used as the colorant. By including white titanium oxide particles in the colored resin layer 13a, light is easily scattered in the colored resin layer 13a, and the photoelectric conversion efficiency of the solar cell module 1 can be further increased.
　本実施形態では、透明樹脂層１３ｂのメルトフローレート（ＭＦＲ）が着色樹脂層１３ａのＭＦＲよりも小さい。すなわち、透明樹脂層１３ｂを構成する樹脂と、着色樹脂層１３ａを構成する樹脂とは、透明樹脂層１３ｂのメルトフローレート（ＭＦＲ）が着色樹脂層１３ａのＭＦＲよりも小さくなるような組み合わせとされている。透明樹脂層１３ｂのメルトフローレート（ＭＦＲ）が着色樹脂層１３ａのＭＦＲよりも０．７ｇ／１０分以上小さいことがより好ましく、１．０ｇ／１０分以上小さいことが好ましい。 In the present embodiment, the melt flow rate (MFR) of the transparent resin layer 13b is smaller than the MFR of the colored resin layer 13a. That is, the resin constituting the transparent resin layer 13b and the resin constituting the colored resin layer 13a are combined such that the melt flow rate (MFR) of the transparent resin layer 13b is smaller than the MFR of the colored resin layer 13a. ing. The melt flow rate (MFR) of the transparent resin layer 13b is more preferably 0.7 g / 10 min or less and preferably 1.0 g / 10 min or less than the MFR of the colored resin layer 13a.
　具体的には、透明樹脂層１３ｂを構成する樹脂は、例えば、エチレン性不飽和シラン化合物、エチレン性不飽和シラン化合物とα－オレフィンとの共重合体及びシラン変性樹脂からなる群から選ばれた少なくともひとつであることが好ましい。 Specifically, the resin constituting the transparent resin layer 13b was selected from the group consisting of, for example, an ethylenically unsaturated silane compound, a copolymer of an ethylenically unsaturated silane compound and an α-olefin, and a silane-modified resin. At least one is preferable.
　エチレン性不飽和シラン化合物としては、例えば、ビニルトリメトキシシラン、ビニルトリエトキシシラン、ビニルトリプロポキシシラン、ビニルトリカルボキシシランなどがある。 Examples of the ethylenically unsaturated silane compound include vinyltrimethoxysilane, vinyltriethoxysilane, vinyltripropoxysilane, and vinyltricarboxysilane.
　α－オレフィンとしては、例えば、エチレン、プロピレン、１－ブテン、イソブチレン、１－ペンテン、２－メチル－１－ブテンなどがある。 Examples of the α-olefin include ethylene, propylene, 1-butene, isobutylene, 1-pentene and 2-methyl-1-butene.
　シラン変性樹脂としては、例えば、シラン変性エチレン、シラン変性ウレタン、シラン変性フェノール、シラン変性エポキシなどがある。 Examples of the silane-modified resin include silane-modified ethylene, silane-modified urethane, silane-modified phenol, and silane-modified epoxy.
　一方、着色樹脂層１３ａを構成する樹脂は、例えば、エチレン・酢酸ビニル共重合体、エチレン・エチルアクリレート共重合体、シリコーン樹脂、エポキシ樹脂、ポリビニルブチラール、エチレンビニルアルコール共重合体、アクリル樹脂、ポリエチレン及びポリプロピレンからなる群から選ばれた少なくともひとつであることが好ましい。 On the other hand, the resin constituting the colored resin layer 13a is, for example, ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, silicone resin, epoxy resin, polyvinyl butyral, ethylene vinyl alcohol copolymer, acrylic resin, polyethylene. And at least one selected from the group consisting of polypropylene.
　なお、本発明において、「メルトフローレート（ＭＦＲ）とは、熱可塑性樹脂の溶融時の流動性を数値で表したものである。 In the present invention, “melt flow rate (MFR)” is a numerical value representing the fluidity of a thermoplastic resin during melting.
　メルトフローレート（ＭＦＲ）の算出は、以下の方法により行うことができる。すなわち、一定の時間間隔で押し出し物を切り取り、一連の切り取り量を測定し、以下（１）の計算式によりメルトフローレート（ＭＦＲ）を求めることができる。 Calculation of melt flow rate (MFR) can be performed by the following method. That is, the extrudate is cut at regular time intervals, a series of cut amounts are measured, and the melt flow rate (MFR) can be obtained by the following formula (1).
　ＭＦＲ（ｇ／１０分）＝６００×ｍ／ｔ・・・（１）
　但し、上記式（１）において、
　ＭＦＲ：メルトフローレート（ｇ／１０分）
　ｍ：切り取り片の平均質量
　ｔ：試料の切り取り時間間隔（秒）
６００：基準時間の秒数（＝１０分） MFR (g / 10 min) = 600 × m / t (1)
However, in the above formula (1),
MFR: Melt flow rate (g / 10 min)
m: Average mass of the cut piece t: Sample cut time interval (seconds)
600: Reference time in seconds (= 10 minutes)
　（太陽電池モジュール１の製造方法）
　次に、図３を参照しながら、太陽電池モジュール１の製造方法の一例について説明する。 (Method for producing solar cell module 1)
Next, an example of a method for manufacturing the solar cell module 1 will be described with reference to FIG.
　まず、図３に示すように、透明基板１０の上に、透明樹脂層１３ｂを構成するための透明樹脂シート２２と、太陽電池セルユニット２と、着色樹脂層１３ａを構成するための着色樹脂シート２１と、バックシート１１とをこの順番で積層することにより、積層体３０を形成する（積層体形成工程）。 First, as shown in FIG. 3, on the transparent substrate 10, the transparent resin sheet 22 for constituting the transparent resin layer 13b, the solar cell unit 2, and the colored resin sheet for constituting the colored resin layer 13a. The laminated body 30 is formed by laminating 21 and the back sheet 11 in this order (laminated body forming step).
　次に、積層体３０を加熱しながらラミネートすることにより、太陽電池モジュール１を完成させることができる（ラミネート工程）。 Next, the solar cell module 1 can be completed by laminating the laminate 30 while heating (laminating step).
　本実施形態では、上述のように、透明樹脂層１３ｂのメルトフローレート（ＭＦＲ）が着色樹脂層１３ａのＭＦＲよりも小さい。このため、着色樹脂シート２１として、ラミネート工程において透明樹脂シートよりも低い粘度を有する樹脂シートを用いる。 In the present embodiment, as described above, the melt flow rate (MFR) of the transparent resin layer 13b is smaller than the MFR of the colored resin layer 13a. For this reason, as the colored resin sheet 21, a resin sheet having a viscosity lower than that of the transparent resin sheet is used in the laminating step.
　ところで、積層体をラミネートした場合は、透明樹脂シート及び着色樹脂シートの積層体端部に位置する部分が変形して薄くなる。このため、ラミネート工程においては、透明樹脂シート及び着色樹脂シートの積層体端部に位置する部分の一部が積層体中央に向かって流動する。また、透明基板は、比較的硬質である一方、樹脂シートは、可撓性を有する。このため、樹脂シート側に設けられた着色樹脂シートは、積層体中央側かつ透明基板側に向かって流動しようとする。従って、太陽電池セルユニットの外縁部に位置する太陽電池セルの受光面の上に着色樹脂シートが回り込んでしまう虞がある。 By the way, when the laminated body is laminated, the part located at the end of the laminated body of the transparent resin sheet and the colored resin sheet is deformed and thinned. For this reason, in a lamination process, a part of part located in the laminated body edge part of a transparent resin sheet and a colored resin sheet flows toward the laminated body center. The transparent substrate is relatively hard, while the resin sheet has flexibility. For this reason, the colored resin sheet provided on the resin sheet side tends to flow toward the center of the laminate and the transparent substrate side. Therefore, there is a possibility that the colored resin sheet may wrap around the light receiving surface of the solar battery cell positioned at the outer edge of the solar battery cell unit.
　しかしながら、本実施形態では、透明樹脂層１３ｂのＭＦＲが着色樹脂層１３ａのＭＦＲよりも小さく、ラミネート工程において、着色樹脂シート２１の粘度が、透明樹脂シート２２の粘度よりも低い。従って、ラミネート工程において太陽電池セル１２の受光面１２ａの上に回り込もうとする着色樹脂シート２１は、粘度の高い透明樹脂シート２２により弾かれる。その結果、太陽電池セル１２の受光面１２ａの上に着色樹脂シート２１が回り込むことを効果的に抑制することができる。よって、改善された光電変換効率を有する太陽電池モジュール１を製造することができる。 However, in this embodiment, the MFR of the transparent resin layer 13b is smaller than the MFR of the colored resin layer 13a, and the viscosity of the colored resin sheet 21 is lower than the viscosity of the transparent resin sheet 22 in the laminating step. Therefore, the colored resin sheet 21 that attempts to wrap around the light receiving surface 12a of the solar battery cell 12 in the laminating process is repelled by the transparent resin sheet 22 having a high viscosity. As a result, it is possible to effectively suppress the colored resin sheet 21 from going around the light receiving surface 12a of the solar battery cell 12. Therefore, the solar cell module 1 having improved photoelectric conversion efficiency can be manufactured.
　太陽電池セル１２の受光面１２ａの上に着色樹脂シート２１が回り込むことをより効果的に抑制する観点からは、透明樹脂層１３ｂのＭＦＲ（＝透明樹脂シート２２のＭＦＲ）が、着色樹脂層１３ａのＭＦＲ（＝着色樹脂シート２１のＭＦＲ）よりも０．７ｇ／１０分以上小さいことが好ましく、１．０ｇ／１０分以上小さいことがより好ましい。 From the viewpoint of more effectively suppressing the colored resin sheet 21 from wrapping around the light receiving surface 12a of the solar battery cell 12, the MFR of the transparent resin layer 13b (= MFR of the transparent resin sheet 22) is the colored resin layer 13a. It is preferably 0.7 g / 10 min or less, more preferably 1.0 g / 10 min or less than the MFR (= MFR of the colored resin sheet 21).
１…太陽電池モジュール
２…太陽電池セルユニット
３…太陽電池セルストリング
１０…透明基板
１１…バックシート
１２…太陽電池セル
１２ａ…受光面
１２ｂ…裏面
１３…充填剤層
１３ａ…着色樹脂層
１３ｂ…透明樹脂層
１４…配線材
２１…着色樹脂シート
２２…透明樹脂シート
３０…積層体 DESCRIPTION OF SYMBOLS 1 ... Solar cell module 2 ... Solar cell unit 3 ... Solar cell string 10 ... Transparent substrate 11 ... Back sheet 12 ... Solar cell 12a ... Photosensitive surface 12b ... Back surface 13 ... Filler layer 13a ... Colored resin layer 13b ... Transparent Resin layer 14 ... wiring material 21 ... colored resin sheet 22 ... transparent resin sheet 30 ... laminate

Claims (5)

  1. 　透明基板と、透明樹脂層と、太陽電池セルと、着色樹脂層と、バックシートとがこの順番で積層され、前記太陽電池セルの受光面が前記透明樹脂層側を向き、前記太陽電池セルの裏面が前記着色樹脂層側を向き、
    　前記透明樹脂層のＭＦＲが、前記着色樹脂層のＭＦＲよりも小さい、太陽電池モジュール。     A transparent substrate, a transparent resin layer, a solar battery cell, a colored resin layer, and a back sheet are laminated in this order, the light receiving surface of the solar battery cell faces the transparent resin layer, and the solar battery cell The back side faces the colored resin layer side,
    The solar cell module in which the MFR of the transparent resin layer is smaller than the MFR of the colored resin layer.
  2. 　前記透明樹脂層のＭＦＲが、前記着色樹脂層のＭＦＲよりも０．７ｇ／１０分以上小さい、請求項１に記載の太陽電池モジュール。 The solar cell module according to claim 1, wherein the MFR of the transparent resin layer is 0.7 g / 10 min or less smaller than the MFR of the colored resin layer.
  3. 　前記透明樹脂層のＭＦＲが、前記着色樹脂層のＭＦＲよりも１．０ｇ／１０分以上小さい、請求項１に記載の太陽電池モジュール。 The solar cell module according to claim 1, wherein the MFR of the transparent resin layer is 1.0 g / 10 min or less smaller than the MFR of the colored resin layer.
  4. 　前記透明樹脂層は、エチレン性不飽和シラン化合物、エチレン性不飽和シラン化合物とα－オレフィンとの共重合体及びシラン変性樹脂からなる群から選ばれた少なくともひとつの樹脂を含み、
    　前記着色樹脂層は、エチレン・酢酸ビニル共重合体、エチレン・エチルアクリレート共重合体、シリコーン樹脂、エポキシ樹脂、ポリビニルブチラール、エチレンビニルアルコール共重合体、アクリル樹脂、ポリエチレン及びポリプロピレンからなる群から選ばれた少なくともひとつの樹脂を含む、請求項１～３に記載の太陽電池モジュール。     The transparent resin layer includes at least one resin selected from the group consisting of an ethylenically unsaturated silane compound, a copolymer of an ethylenically unsaturated silane compound and an α-olefin, and a silane-modified resin,
    The colored resin layer is selected from the group consisting of ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, silicone resin, epoxy resin, polyvinyl butyral, ethylene vinyl alcohol copolymer, acrylic resin, polyethylene and polypropylene. The solar cell module according to claim 1, further comprising at least one resin.
  5. 　透明基板と、透明樹脂シートと、太陽電池セルと、着色樹脂シートと、バックシートとをこの順番で積層させた積層体を形成し、前記太陽電池セルの受光面が前記透明樹脂シート側を向き、前記太陽電池セルの裏面が前記着色樹脂シート側を向き、
    　前記透明樹脂シートが前記着色樹脂シートよりも高い粘度を有し、
    　前記積層体を加熱しながらラミネートする太陽電池モジュールの製造方法。     A laminated body is formed by laminating a transparent substrate, a transparent resin sheet, a solar battery cell, a colored resin sheet, and a back sheet in this order, and the light receiving surface of the solar battery cell faces the transparent resin sheet. The back surface of the solar cell faces the colored resin sheet side,
    The transparent resin sheet has a higher viscosity than the colored resin sheet;
    The manufacturing method of the solar cell module which laminates the said laminated body, heating.
PCT/JP2012/051149 2011-01-31 2012-01-20 Solar cell module and method for manufacturing same WO2012105331A1 (en)

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